Secondary containment system for DEF storage container

ABSTRACT

A secondary containment system used to transport and store a tank containing diesel exhaust fluid. The secondary containment system having a containment body comprising an end wall, a back wall, two side walls, a bottom, and a top, wherein the walls are integral to the bottom, and wherein the top can be displaced from the containment body. The containment body is constructed of a three-layer configuration comprising an inner layer, an outer layer, and a central layer sandwiched therebetween. The inner layer defines a chamber in which the tank containing diesel exhaust fluid is stored. The chamber is sized and shaped so that the tank is positioned in the chamber and defines a void between walls of the inner layer and the tank containing diesel exhaust fluid. The inner layer and outer layer are preferably constructed of a UV protected polyethylene, and the central layer is constructed of a 2″-2 lb. density polyurethane insulation material having an R17 value.

CROSS REFERENCES TO RELATED APPLICATIONS

U.S. Provisional Application for Patent No. 61/271,919, filed Jul. 28, 2009, with title “Pump Island DEF Dispenser” which is hereby incorporated by reference. Applicant claim priority pursuant to 35 U.S.C. Par. 119(e)(i).

Statement as to Rights to Inventions Made Under Federally Sponsored Research and Development

Not Applicable.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates generally to a transport and storage container for liquids and more particularly to a secondary containment for transporting and storing Diesel Exhaust Fluid (DEF).

2. Brief Description of Prior Art.

In 1990, Congress passed and President George H. W. Bush signed amendments to the Clean Air Act that directed the U.S. Environmental Protection Agency (EPA) to regulate air pollutants from a variety of industrial and commercial sources including motor vehicles.

Among the air pollutants EPA regulates under the authority of the Clean Air Act are particulate matter (PM) and Nitrogen Oxides (NOx) by products of diesel exhausts that are precursors to smog. PM has been linked to higher incidences of childhood asthma, among other health hazards. The more sulfur motor fuel contains, the more PM it produces when burned. NOx is produced during the process of high-temperature combustion such as is present in a motor vehicle engine, and can react with sunlight along with volatile organic compounds to form smog.

Exhaust treatment systems work hand in hand with reductions in the amount of sulfur in diesel fuel to reduce PM and NOx. In order to meet EPA regulations on limiting emissions of PM and NOx from their vehicle exhaust system many of the engine manufactures have or will adopt a pre-exhaust treatment system such as Selective Catalytic Reduction (SCR). SCR engines require a steady flow of Diesel Exhaust Fluid (DEF)—comprised of a solution of urea and water—to convert engine emissions into harmless levels of nitrogen and water vapor. As such, DEF will be required in most diesel vehicles in order to replenish the clean exhaust systems using SCR.

The term “diesel exhaust fluid” (DEF) only recently entered the United States fleet industry with the advent of a particular type of clean exhaust system, SCR. Because these clean exhaust systems are sensitive and the material must remain pure, quality is a key concern for anyone marketing or handling DEF. In this regard, distribution network certification systems are being established to meet the need for quality DEF through truck stops and retail outlets and to accommodate a wide variety of dispensing options.

DEF is not an additive, and is not mixed with diesel fuel. In a vehicle outfitted with an SCR system, DEF has a separate on-board tank (6-10 gallons on light-duty vehicles; 10-30 gallons on heavy-duty vehicles). From its storage tank, DEF is pumped through a filter and injector and then, into the exhaust system. In the after treatment system, the heat from the exhaust hydrolyzes the urea into two components: Anhydrous Ammonia and CO2. The gas mixture of ammonia and NOx passes across the catalyst and reduces them to elemental nitrogen and water, harmless since air is composed of 78% elemental nitrogen. The additional CO2 emitted due to urea decomposition is offset by enhanced fuel economy. A gallon of diesel emits ten times more CO2 than a gallon of DEF.

DEF is distributed in the fleet marketplace through truck stops along interstate routes and through truck terminals. Fuel oil distributors generally vend DEF in mini-bulk storage containers that are delivered to a fuel island and hooked to a dispensing pump for retail at service locations.

As stated, the integrity of DEF through the supply chain is critical. Purity and concentration must be maintained through the dispensing equipment, storage and handling, including any small packaging for DEF. Supply-chain partners must undergo a rigorous process to handle the fluid properly. It can therefore be appreciated that there exists a continuing need for a transport and storage system for storing DEF in order to ensure proper DEF dispensing operability especially where extreme temperature conditions exist, and handling DEF for retail installation. It is also imperative that the transport and storage system maintain the purity and concentration to satisfy EPA standards. The present invention meets this need.

SUMMARY OF THE INVENTION

A secondary containment system used as a transport and storage container for storing a tank containing DEF. The secondary containment system is comprised of a three-layer configuration comprising an inner layer, an outer layer, and a central layer sandwiched between the inner and outer layers. The inner and outer layers are constructed of a first material, preferably a UV protected polyethylene; and, the central layer is constructed of a second material, preferably a 2″-2 lb. density polyurethane insulation material having an R17 value.

The inner layer defines a chamber in which the tank containing the DEF is stored. The chamber is sized and shaped so that the DEF tank is positioned in the chamber and defines a void between the side walls of the inner layer and the DEF storage tank, the void is defined for receiving a heating unit in order to prevent the DEF, when storing, from freezing in extreme cold temperatures.

The inner, outer and central layers that define the secondary containment system have the primary task of maintaining the temperature of the DEF storage tank during transport and storage. The secondary containment system including the central layer assists in insulating all sides of the DEF tank from varying temperature conditions. In addition, the three-layer containment system protects the DEF storage tank during transport and storage.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a preferred embodiment of the present invention, a secondary containment system for a DEF storage container.

FIG. 2 is an end sectional view of the secondary containment system of FIG. 1.

FIG. 3 is an end sectional view of an alternate embodiment of the secondary containment system for a DEF storage container.

DESCRIPTION OF THE PREFERRED EMBODIMENT

The apparatus of the present invention is directed to a transport and storage containment system for storing and handling diesel exhaust fluid (DEF). More particularly, the present invention discloses a secondary containment system that stores and protects the tank containing DEF. In the preferred embodiment, the secondary containment system with the stored DEF is delivered to a fuel island and hooked up to a dispensing pump for retail through truck stops alongside interstate routes, through truck terminals, and other retail outlets. In the broadest context, the secondary containment system for DEF storage container as disclosed consists of components configured and correlated with respect to each other so as to obtain the desired objective.

Referring to FIGS. 1-2, the present invention designated as numerical 10, discloses a secondary containment system which is used as a transport and storage container for storing a tank 100 containing DEF. The container 10 of the present invention includes an end wall 12, a back wall 14, and two side walls 16, 17 as well as a bottom 19, and a top 21. The walls 12, 14, 16 and 17 are integral to the bottom 19. The top 21 can be displaced.

The end wall 12, the back wall 14, the side walls 16, 17, as well as the bottom 19 and the top 21 are comprised of a three-layer configuration comprising an inner layer 25, a central layer 30, and an outer layer 35, the central layer 30 being sandwiched between the inner and outer layers 25, 35. The inner layer 25 and the central layer 30 are wholly inside the outer layer 35. The manufacturing of the inner and outer layers 25, 35 is suitably through an injection moulding process.

As shown in FIG. 2, the inner layer 25 defines a chamber 40 in which the tank 100 containing the DEF is stored. The chamber 40 is sized and shaped so that the tank 100 is positioned in the chamber 40 and defines a void 42 between the walls 12, 14, 16, 17 of the inner layer 25 and the DEF storage tank 100. As will be understood, the void 42 is defined for receiving a heating unit (not shown) in order to prevent the DEF, when storing, from freezing in extreme cold temperatures.

The inner layer 25 and outer layer 35 is preferably constructed of a UV protected polyethylene. The central layer 30 is preferably constructed of a 2″-2 lb. density polyurethane insulation material having an R17 value. To clarify, the end wall 12, the back wall 14, the side wall 16, 17, as well as the bottom 19 and the top 21 are all comprised of the three-layer configuration as described.

The layers 25, 30 and 35 that define the container 10 have the primary task of maintaining the temperature of the DEF storage tank 100 during transport and storage. Unlike prior art DEF storage tanks, the secondary containment system 10 includes the central layer 30 to assists in insulating all sides of the DEF tank 100 from varying temperature conditions. While it is known to install a heating unit (not shown) adjacent the DEF storage tank in order to avoid freezing, the applicant has found that the use of the R17 insulated system of the present invention results in less energy used for maintaining and heating the DEF temperature resulting in significant cost savings. In addition, the layers 25, 30 and 35 provide layers of protecting the storage tank 100 during transport and storage.

The secondary containment system according to the invention is used as follows:

Once the top 21 of the secondary containment system 10 is lifted off the container 10, the storage tank 100 containing the DEF is placed within the chamber 40 of the inner layer 25.

After the tank 100 is positioned in the chamber 40, the top 21 is closed.

The secondary containment system 10 having the tank 100 containing the DEF is then transported and delivered to a fuel island to be hooked to a dispensing pump.

The secondary containment system 10 protects against any type of mechanical action from outside by use of the defined three-layer system, and the extremely durable materials used in construction. One or more blows struck as a test against the outer layer 35 were withstood without damage to the storage tank 100 disposed in the chamber 40.

The system 10 is further effective in preventing the DEF from freezing during short periods of time in extreme cold conditions, and without an auxiliary heating unit. The R17 insulated system has withstood and protected the DEF in freezing temperatures for at least three (3) days without the use of a heating unit, and continued during this time to maintain its dispensing operability. Thus, when using the present invention, it is possible to protect the DEF from freezing temperatures should for example, the system's heating source malfunction.

The secondary containment system 10 is also safe in very warm temperatures. Again, the R17 insulated system protects the DEF in order to maintain its dispensing operability.

The secondary containment system 10 is designed to grow with the user's business, and preferably has a 400 to 1000 gallon usable storage capacity.

Alternatively, as shown in FIG. 3, the secondary containment system 200 includes a containment body 205 having an end wall 12, a back wall (not shown), and two side walls 16, 17 as well as a bottom 19, and a top 21. The walls 12, 14, 16 and 17 are integral to the bottom 19. The top 21 of the containment body 205 can be displaced from the body 205.

The container body 205 defines an inner layer 210 integral to an outer layer 220. An inter-space between the inner and outer layers 210, 220 is defined by a central layer 215. The manufacturing of the container body 205 is suitably through an injection moulding process.

The inner layer 210 defines a chamber 240 in which the tank 100 containing the DEF is stored. The chamber 240 is sized and shaped so that the tank 100 is positioned in the chamber 240 and defines a void 242 between the walls 12, 14, 16, 17 of the inner layer 210 and the DEF storage tank 100. The void 242 is defined for receiving a heating unit (not shown) in order to prevent the DEF, when storing, from freezing in extreme cold temperatures.

The container body 205 is preferably constructed of UV protected polyethylene. The central layer 215 is preferably constructed of a 2″-2 lb. density polyurethane insulation material having an R17 value.

The body 205 having the central layer 215 has the primary task of maintaining the temperature of the DEF storage tank 100 during transport and storage. Unlike prior art DEF storage tanks, the addition of the central layer 215 assists in insulating all sides of the DEF tank 100 from varying temperature conditions. While it is known to install a heating unit (not shown) adjacent the DEF storage tank in order to avoid freezing, the applicant has found that the use of the R17 insulated system of the present invention results in less energy used for maintaining and heating the DEF temperature resulting in significant cost savings. In addition, the container body 205 provides layers of protecting the storage tank 100 during transport and storage.

Although the above description contains many specificities, these should not be construed as limiting the scope of the invention but is merely providing illustrations of some of the presently preferred embodiments of this invention. As such, it is to be understood that the present invention is not limited to the embodiments described above, but encompasses any and all embodiments within the scope of the claims. 

1. A secondary containment system used to transport and store a tank containing diesel exhaust fluid, said secondary containment system comprising: a containment body comprising an end wall, a back wall, two side walls, a bottom, and a top, wherein the end wall, the back wall and the side walls are integral to the bottom, and wherein the top can be displaced from the containment body, wherein the end wall, the back wall, the side walls, the bottom and the top are comprised of a three-layer configuration comprising an inner layer, a central layer and an outer layer, the central layer being sandwiched between the inner and outer layers, and wherein the inner layer and the central layer are wholly inside the outer layer, wherein the inner layer defines a chamber in which a tank containing diesel exhaust fluid is stored, said chamber is sized and shaped so that the tank is positioned in the chamber and defines a void between walls of the inner layer and the tank containing diesel exhaust fluid, wherein the inner and outer layers are constructed of a first material, and the central layer is constructed of a second material preferably an insulation material.
 2. The containment system as recited in claim 1, wherein said tank containing diesel exhaust fluid is completely enclosed in said secondary containment system.
 3. The containment system as recited in claim 2, wherein said first material is a UV protected polyethylene.
 4. The containment system as recited in claim 3, wherein said second material is a 2″-2 lb. density polyurethane insulation material.
 5. The containment system as recited in claim 4, wherein said second material is an insulation material having an R17 value.
 6. A secondary containment system used to transport and store a tank containing diesel exhaust fluid, said secondary containment system comprising: a containment body comprising an end wall, a back wall, two side walls, a bottom, and a top, wherein the end wall, the back wall and the side walls are integral to the bottom, and wherein the top can be displaced from the containment body, wherein said containment body completely encloses a tank containing diesel exhaust fluid; wherein the container body defines an inner layer integral to an outer layer, an inter-space between the inner and outer layers is defined by a central layer; wherein the inner layer defines a chamber in which the tank containing diesel exhaust fluid is stored, said chamber is sized and shaped so that the tank is positioned in the chamber and defines a void between walls of the inner layer and the tank containing diesel exhaust fluid; wherein the inner layer and outer layers are constructed of a plastic material, and the central layer is constructed of an insulation material.
 7. The containment system as recited in claim 6, wherein said inner and outer layers are constructed of a UV protected polyethylene.
 8. The containment system as recited in claim 7, wherein said central layer is constructed of a 2″-2 lb. density polyurethane insulation material.
 9. The containment system as recited in claim 8, wherein said central layer is an insulation material having an R17 value.
 10. A secondary containment system used to transport and store a tank containing diesel exhaust fluid, said secondary containment system comprising: an enclosure that completely encloses a tank containing diesel exhaust fluid, said enclosure including a top that can be displaced, said enclosure further defines an inner wall, an outer wall, and a center disposed between said inner and outer walls, said inner wall defines a chamber sized and shape to receive the tank containing diesel exhaust fluid, wherein said inner and outer walls are constructed of a first material, and said center is disposed of a second material.
 11. The containment system as recited in claim 10, wherein said chamber further defines a void between the inner walls and the stored tank containing diesel exhaust fluid.
 12. The containment system as recited in claim 10, wherein said first material is a UV protected polyethylene.
 13. The containment system as recited in claim 12, wherein said second material is a 2″-2 lb. density polyurethane insulation material.
 14. The containment system as recited in claim 13, wherein said second material is an insulation material having an R17 value. 